Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
  • B29D99/00—Subject matter not provided for in other groups of this subclass
  • B29D99/0003—Producing profiled members, e.g. beams
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
  • B29C51/02—Combined thermoforming and manufacture of the preform
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/28—Shaping operations therefor
  • B29C70/40—Shaping or impregnating by compression not applied
  • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]

Definitions

• Parts made of reinforced thermoplastic composite materials may have smaller strength reductions at higher in- service temperatures than parts made of reinforced thermoset composite materials.
• Reinforced thermoplastic composite materials have higher toughness, including fracture toughness and Interlaminar Tension Strength (ILT), than reinforced thermoset composite materials.
• thermoplastics also offer certain advantages with respect to plies of reinforcing fibers pre-impregnated with resin. Unlike thermoset materials, thermoplastic materials do not have a shelf life and do not require refrigeration prior to processing. Thermoplastic materials also do not produce significant volatiles during consolidation.
• a method of fabricating a reinforced thermoplastic composite part comprises moving a laminate of reinforcing fibers embedded in a thermoplastic matrix for sequential operations through a heating station and then a forming station.
• the heating station is used to soften the thermoplastic matrix in a portion of the laminate while the forming station is used to impart a geometry to a portion of the laminate whose thermoplastic matrix had just been softened.
• the softening and the forming are performed simultaneously on different portions of the laminate.
• a method of comprises moving a ply stack of reinforcing fibers pre-impregnated with thermoplastic resin sequentially through consolidating, heating and forming stations to consolidate the plies into a laminate, soften thermoplastic resin in the laminate without causing the resin to flow, and impart a part geometry.
• the consolidating, softening, and forming are performed simultaneously on different portions of the laminate.
• a fabrication system comprises a heating station for softening a thermoplastic matrix of a reinforced thermoplastic composite laminate; a forming station for imparting a geometry to a portion of the laminate whose thermoplastic matrix had just been softened; and a conveyor for moving the laminate sequentially through the stations so that the softening and forming are performed simultaneously on different portions of the laminate.
• thermoplastic composite part comprising moving a laminate of reinforcing fibers embedded in a thermoplastic matrix for sequential operations through a heating station and then a forming station, and using the heating station to soften the thermoplastic matrix in a portion of the laminate while using the forming station to impart a geometry to a portion of the laminate whose thermoplastic matrix had just been softened, wherein the softening and the forming are performed simultaneously on different portions of the laminate.
• the method further comprises moving a ply stack of reinforcing fibers pre-impregnated with thermoplastic resin through a consolidating station to consolidate the plies into the laminate prior to moving through said heating and said forming stations.
• the method further comprises forming a downstream portion of the ply stack while upstream portions of the ply stack are being consolidated, heated, and formed.
• the method further comprises wherein infrared energy is used to consolidate the plies and soften the thermoplastic matrix.
• the method further comprises wherein the forming includes using multi-stage tooling to impart different geometries to the laminate.
• the method further comprises wherein the forming is performed as a multi-shot stamping operation.
• the method further comprises wherein the forming is performed with tools that are heated integrally.
• the method further comprises further comprising adding attachment features to the formed portion of the laminate.
• the method further comprises wherein a conveyor is used to move the laminate through the stations.
• a flexible polymer film is used as a conveyor belt to support the laminate, and wherein the film is peeled from the part after the part has been formed.
• the method further comprises wherein the forming is performed with a tool that is moved along with the laminate.
• the method further comprises wherein the laminate is formed into an integrally stiffened part having continuous or stretch broken fiber reinforcement.
• method comprising moving a ply stack of reinforcing fibers pre-impregnated with thermoplastic resin sequentially through consolidating, heating and forming stations to consolidate the plies into a laminate, soften thermoplastic resin in the laminate without causing the resin to flow, and impart a part geometry, wherein the consolidating, softening, and forming are performed simultaneously on different portions of the laminate.
• the method further comprises forming a downstream portion of the ply stack while upstream portions of the ply stack are being consolidated, heated, and formed.
• a fabrication system comprising a heating station for softening a thermoplastic matrix of a reinforced thermoplastic composite laminate, a forming station for imparting a geometry to a portion of the laminate whose thermoplastic matrix had just been softened, and a conveyor for moving the laminate sequentially through the stations so that the softening and forming are performed simultaneously on different portions of the laminate.
• the fabrication system further comprises a consolidating station for consolidating an unconsolidated ply stack of reinforcing fibers pre- impregnated with a thermoplastic into the laminate; wherein the conveyor moves the unconsolidated ply stack to the consolidating station and then moves the laminate to the heating station.
• the fabrication system further comprises a station for forming a portion of the ply stack as another portion is being consolidated.
• the fabrication system further comprises wherein the heating station includes upper and lower pre-heating zones, and upper and lower heating zones.
• the fabrication system further comprises wherein the tooling station includes first-stage tooling for forming an initial part geometry, and second-stage tooling for changing the initial geometry to increase part stiffness.
• the fabrication system further comprises further comprising a controller for controlling operation of the conveyor, the heating station, and the forming station.
• FIGS. 1 and 2 are illustrations of methods of forming reinforced
• thermoplastic composite parts thermoplastic composite parts.
• FIGS. 3 and 4 are illustrations of systems for forming reinforced thermoplastic composite parts.
• FIG. 5 is a flow diagram of aircraft production and service methodology.
• FIG. 6 is a block diagram of an aircraft.
• FIG. 1 illustrates a method of fabricating a reinforced thermoplastic composite part.
• the part includes plies of reinforcing fibers embedded in a thermoplastic matrix.
• the reinforcing fibers include, but are not limited to, carbon fibers, glass fibers, and Kevlar® aramid fibers.
• the reinforcing fibers may be continuous, woven, chopped, or stretch broken in form.
• the thermoplastic include, but are not limited to, Polyetherimide (PEI), Polyphenylene Sulfide (PPS), and Polyaryletherketones (e.g., PEEK, PEKK).
• the method of FIG. 1 involves forming a ply stack 101 and moving the ply stack 101 (in the direction of the arrow) through a sequence of stations 120-150 while performing operations at each of those stations 120-150.
• the operations include, but are not limited to, consolidating, heating, forming, and finishing. These operations are performed in sequence. However, these different operations may be performed simultaneously on different portions of the ply stack 101 .
• plies 100 of reinforcing fibers are stacked up to form an unconsolidated portion 102 of the ply stack 101 .
• plies 100 are pre-impregnated with a thermoplastic resin, and these "pre-pregs" are stacked up on a forming tool.
• plies 100 of dry fibers are interleaved with sheets of thermoplastic film. There is no need to refrigerate thermoplastic materials prior to stacking.
• the unconsolidated portion 102 of the ply stack 101 is moved to a consolidating station 120 for consolidation into a laminate 104.
• the consolidation is performed under sufficient pressure and temperature to remove voids in the resin and consolidate the plies 100 together.
• the temperature is sufficient to soften the thermoplastic resin without causing it to flow. Issues commonly associated with the curing of thermoset composites (e.g., vacuum bagging, volatiles creating porosity in the consolidated laminate, and environmental, health, and safety concerns about evolved gasses) are minimized or essentially eliminated.
• the ply stack 101 is moved until the laminate 104 arrives at a heating station 130.
• the heating station 130 is used to soften the thermoplastic matrix in the laminate 104 without causing it to flow. The heating at this point will facilitate the subsequent forming of the laminate 104.
• the ply stack 101 is moved again until the heated laminate 106 arrives at a forming station 140.
• the forming station 140 is used to impart a geometry to the heated laminate 106 (whose thermoplastic had just been softened) to produce a formed laminate 108.
• the forming may be performed in a single stage or multiple stages.
• first-stage tooling may impart the same geometry in every detail, but final-stage tooling may add geometry to only certain details.
• the multi-stage forming may be performed as a multi-shot stamping operation, where stamping tools are used sequentially.
• First-stage tooling stage stamps the same geometry in each stiffener.
• Final-stage tooling stamps additional geometry only in certain stiffeners, resulting in stiffeners having variable heights.
• the final stage adds stiffness by changing the geometry of the stiffener itself without adding any additional material to it (thus making the stiffener "integrated").
• the tooling may be integrally heated during forming.
• the tooling may be heated to build up crystallinity of the polymer in the final part.
• the heating also promotes slight ply "slippage", instead of moving heated (e.g., potentially 700°F) thermoplastic material into a cold tool where the material would be instantly frozen, and where internal stresses would then be concentrated.
• the tooling may be maintained at a temperature below the melt point of the thermoplastic. This would cool the heated laminate 106. If multi-stage tooling is used, the first-stage tooling may be maintained at a temperature slightly below, at, or above the melt point of the material, and the final- stage tooling may be maintained at a temperature below the melt point of the
• thermoplastic material These temperatures would cool the heated laminate 106, but still allow for forming.
• Processing parameter such as temperatures, and feed rate are not limited to any particular values. These parameters are a function of resin material, fiber material, number of plies in the stack, etc.
• the tooling may move along with the heated laminate 106 as the heated laminate 106 is being formed.
• the ply stack 101 is moved again until the formed laminate 108 arrives at a finishing station 150.
• attachment features may be added to the formed laminate 108 to produce a finished portion 109 of the part.
• Attachment features include, but are not limited to, inserts, bushings, and heli-coils. Other operations may be performed at the finishing station 150, including, but not limited to, trim,
• NDI nondestructive inspection
• Some or all of these operations may be performed simultaneously on different portions of the ply stack 101 .
• the attachment features may be added to the formed portion 108, while another portion 108 is being formed, while another portion 106 is being heated, while another portion 104 is being consolidated.
• This method enables the fabrication of an elongated thermoplastic consolidated part without having to consolidate the entire part at the same time, and then heat the entire part at the same time, and then form the entire part at the same time.
• This in turn, enables smaller machines to be used to perform the operations. Since the machines are smaller, the problem of heating larger machines is avoided.
• This method is especially useful for the fabrication of large composite parts having complex geometries, such as an integrally stiffened parts having continuous or stretch broken fiber reinforcement.
• the unconsolidated ply stack 102 is completely formed before it is moved to the consolidating station 120.
• plies 100 could be stacked as the other operations (consolidation, heating, and forming) are being performed. For example, a 30 foot long part could be fabricated by a piece of equipment that is 20 feet long. By the time the formed laminate 108 arrives at the finishing station 150, the plies 100 for the last 10 feet of the part have yet to be stacked up. Thus, these other embodiments allow even longer parts to be formed.
• a method herein is not limited to the embodiment of FIG. 1 .
• some embodiments may not include the consolidating station.
• FIG. 2 illustrates an embodiment of a method that does not include a consolidating station.
• the method of FIG. 2 starts with a laminate 200 of reinforcing fibers in a thermoplastic matrix.
• the laminate 200 may be purchased from a supplier or consolidated in a separate process.
• the laminate 200 is heated to soften a portion of the thermoplastic matrix.
• the softened portion is formed.
• the softening and forming may be performed at the same time on different portions of the laminate 200. Finishing (not shown) may also be performed on the laminate 200.
• FIG. 3 illustrates a system 310 for performing the method of FIG.2.
• the system 310 includes a heating station 320, a forming station 330, and a conveyor 340 for moving a laminate (not shown) to the heating station 320 and then the forming station 330.
• the conveyor 340 may include a belt 342 that moves the laminate.
• the conveyor 340 may move the laminate in pulses. That is, the conveyor 340 advances portions of the laminate from one station to the next, and stops until the operations at both stations 320 and 330 have been completed.
• the belt 342 may include a flexible polymer film having the same geometry as the laminate.
• the laminate rests on the film during heating and forming.
• the film may be clamped to keep it taut during the heating and forming.
• the film may be Kapton® polyimide film or other film that remain stable at thermoplastic-melt temperatures.
• the heating station 320 may include banks of heating elements 323 and
• thermoplastic matrix of a composite thermoplastic laminate for emitting infrared energy that softens the thermoplastic matrix of a composite thermoplastic laminate.
• a convection oven may be used.
• banks of infrared heating elements 323 and 325 are generally smaller than convection ovens.
• FIG. 3 shows a heating station 320 that is divided into upper and lower pre-heating zones 322 and 324, and upper and lower heating IR zones 326 and 328. Preheating reduces the risk of damage to the laminate, and it decreases heat up time in the heating zones 326 and 328.
• Preheating reduces the risk of damage to the laminate, and it decreases heat up time in the heating zones 326 and 328.
• the tool sets 332 and 334 may be integrally heated.
• the tools of the sets 332 and 334 may be made of steel, and heating elements may be embedded in the steel tools.
• the system 310 may also include a controller 350 for controlling the operation of the heating station 320, the forming station 330 and the conveyor 340. Operations controlled by the controller 350 include, but are not limited to controlling position and speed of the conveyor 340, temperatures in the heating station 320, and temperature, pressure, and hold times of the tool sets 332 and 334. Inputs to the controller 350 may be provided by sensors such as thermocouples, pressure
• FIG. 4 illustrates a system 410 for performing the method of FIG.1 .
• the system 410 includes a heating station 420, a forming station 430 and a conveyor 440.
• the system 410 further includes a layup station 450 for laying up unconsolidated material. Parameters include ply count, ply orientation, ply splice locations, and ply tack frequency and location.
• Unconsolidated material may be laid up by hand or machine. Automated layup may be performed, for example, by a continuous tape laminator. Manual layup may include tacking the unconsolidated material (e.g., with a heat gun).
• the system 410 further includes a consolidating station 460, which may include upper and lower zones 462 and 464 of infrared elements 463 and 465 that apply heat to the unconsolidated material, and it may include rollers 466 for applying pressure to the unconsolidated material.
• the rollers 466 may be heated to a temperature at or above the melting point of the thermoplastic resin. The resulting laminate is then fed to the heating station 420.
• the system 410 further includes a controller 470 for controlling operation of the conveyor 440, consolidating station 460, heating station 420 and forming station 430. Operations controlled by the controller 470 include, but are not limited to controlling conveyor position and speed, temperatures in the heating station 420, temperature, speed and pressure of the consolidation rollers 466, and tooling
• controller 470 may be provided by sensors such as thermocouples, pressure transducers, and optical sensors. If automated layup is performed, the controller 470 may also control the layup station 450.
• the system 410 can form parts of very long length in the longitudinal (x) direction. If unconsolidated material is feed in pre-pregs from rolls, the part length may be limited by the length of material on that roll. The part may be limited in the z direction by the width of the pre-pregs
• Embodiments herein may be described in the context of an aircraft manufacturing and an exemplary service method 500 as shown in FIG. 5 and an aircraft 602 as shown in FIG. 6.
• the method 500 may include
• a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
• the aircraft 600 produced by exemplary method 500 may include an airframe 610 with a plurality of high-level systems 620 and an interior 630.
• the high-level systems 620 include one or more of a propulsion system 622, an electrical system 624, a hydraulic system 626, and an environmental system 628. Any number of other systems may be included.
• Airframe parts exceeding thirty feet in length may be manufactured by the methods of FIGS. 1 and 2 and the systems of FIGS. 3 and 4.
• an aerospace example is shown, the principles of the invention may be applied to other industries, such as the automotive industry.
• the system and methods embodied herein may be employed during any one or more of the stages of the method 500. For example, components or
• subassemblies corresponding to production process may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 600 is in service. Also, one or more system embodiments, method embodiments, or a combination thereof may be utilized during the production stages, for example, by substantially expediting assembly of or reducing the cost of an aircraft 600.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Manufacturing & Machinery (AREA)
• Moulding By Coating Moulds (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

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